Airbag device and manufacturing method thereof

Abstract

To provide: an airbag device that can easily hold an airbag in an appropriate compressed shape; and a method for manufacturing the airbag device.SOLUTION: An airbag device 10 according to a first aspect of the present invention includes: an airbag 14 which is inflated and deployed by gas supplied from an inflator 12; and a guide member 16 which is connected to a surface of the airbag 14. and regulates an outer circumferential shape of the airbag 14 in an accommodated state.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an airbag device that protects vehicle occupants and pedestrians by inflating and deploying an airbag, and to a method for manufacturing the same. [Background technology]

[0002] It is well known that vehicles are equipped with one or more airbag devices to protect occupants in the event of a vehicle accident. Airbag devices come in a variety of forms, including a driver's airbag device that deploys near the center of the steering wheel to protect the driver, a curtain airbag device that deploys downward inside the window to protect occupants in the event of a lateral impact or a rollover or overturning accident, and a side airbag device that deploys to the side of the occupant (the side of the seat) to protect the occupant in the event of a lateral impact. Airbag devices are also installed in motorcycles in addition to automobiles. The present invention is applicable to various airbag devices.

[0003] The space available to house an airbag device is limited, so it is necessary to compress and house the airbag compactly. It is also important to create an efficient housing shape that fits the space available. For example, the housing space for airbag devices in motorcycles is even more limited than in automobiles, so there are many restrictions on the shape of the airbag to be compressed.

[0004] It is not easy to maintain a specific shape after the airbag is compressed. If the airbag is not compressed properly, it will not be able to be smoothly inserted into the housing. Furthermore, if the airbag's compressed shape is lost, the airbag's deployment behavior may deteriorate and the deployment speed may decrease. Summary of the Invention [Problem to be solved by the invention]

[0005] The present invention has been made in view of the above circumstances, and has an object to provide an airbag device that can easily maintain an airbag in an appropriate compressed shape, and a method for manufacturing an airbag device. [Means for solving the problem]

[0006] In order to achieve the above object, an airbag device according to a first aspect of the present invention includes: an airbag that is inflated and deployed by gas supplied from an inflator; and a guide member that is connected to a surface of the airbag and that regulates the outer peripheral shape of the airbag when stored.

[0007] Here, the "surface of the airbag" refers to the outer surface of one of the base fabrics in the case of an airbag formed into a bag shape by sewing two base fabrics together, for example.

[0008] Furthermore, the "peripheral shape of the airbag when stored" refers to the shape formed by the outer edge of the airbag in a compressed state by folding or rolling it. The term "regulating the outer peripheral shape" includes, for example, forming folds in the airbag based on the outer edge of the guide member, or using it as a starting point when rolling the airbag.

[0009] The airbag can be folded or rolled into a shape that conforms to the outer periphery of the guide member.

[0010] Here, "a shape that conforms to the outer periphery" includes a state in which the outer periphery of the airbag and the outer periphery of the guide member generally match or are generally similar when the compressed airbag is viewed from the guide member side. For example, if a guide member that is rectangular in plan view is used, this includes a case in which the outer periphery of the compressed airbag is also rectangular along the rectangular shape of the guide member.

[0011] The guide member can be made of a material having higher rigidity than the airbag.

[0012] For a relatively flexible airbag that can be inflated by gas, the guide member is made of a highly rigid material such as metal or resin, which makes it possible to reliably maintain the shape of the compressed airbag.

[0013] The inflator is accommodated inside the airbag, and a portion of the guide member can be engaged with the inflator.

[0014] Here, "locking" does not only mean a state in which something is completely fixed, but also a state in which something is caught but cannot be easily released.

[0015] A patch covering the guide member may be provided on the surface of the airbag.

[0016] Here, a "patch" can be expressed as a piece of cloth, such as a patch, that is smaller in area than the airbag when laid flat. The patch can be formed into a bag shape by sewing it to the surface of the airbag, and the guide member can be housed inside. Furthermore, "covering" the guide member includes the state in which the patch is arranged so as to cover the guide member arranged on the surface of the airbag.

[0017] The guide member may be a plate-like member.

[0018] Here, the term "plate-shaped" does not include elongated shapes such as wire, thread, etc. By using a plate-shaped guide member, the shape of the compressed airbag can be maintained flat, improving the airbag retention performance.

[0019] The guide member may be a wire made of metal or resin.

[0020] Here, the term "wire" is different from "plate-like" and includes a thin, thread-like or rod-like shape, and preferably has a certain degree of flexibility so that it can be molded into a desired shape.

[0021] By forming the guide member from a wire, the guide member can be easily connected (engaged) with other components such as a patch by bending a portion of the wire.

[0022] The wire may be configured to define the outer periphery of the guide member.

[0023] By bending the wire, it is possible to easily adjust and change the outer peripheral shape of the guide member.

[0024] The wire can be positioned by engaging a portion of the wire with a stud bolt of the inflator.

[0025] To engage the wire with the stud bolt, for example, the wire can be wrapped around or hooked onto the stud bolt.

[0026] A plurality of loop-shaped wire holding members for holding the wire may be provided on the surface of the airbag.

[0027] Here, the "loop-shaped wire holding member" can be a strip of fabric made of the same or similar fabric as the airbag, and can be made into a loop by sewing both ends of the strip of fabric to the surface of the airbag. Then, by passing the wire through the loop-shaped wire holding member, the wire is held on the surface of the airbag.

[0028] A hook portion may be formed on a portion of the wire, the hook portion protruding in a direction away from the surface of the airbag.

[0029] The "hook" can be formed by bending a part of the wire into a U-shape. Alternatively, the protruding tip of the U-shape can be further bent in one direction to form a hook shape.

[0030] A patch covering the wire is provided on the surface of the airbag, and a patch opening through which the hook portion passes can be formed in the patch.

[0031] By forming an opening in the patch and passing the hook portion of the wire through it, the positional relationship between the patch and the wire is maintained, and unwanted movement or deformation of the wire within the patch can be prevented.

[0032] The airbag may further include a cover member that covers the outer periphery of the airbag in a housed state, and the cover member may be formed with a cover opening through which the hook portion protruding from the patch opening passes.

[0033] Here, the "cover member" can be a wrapping cloth-like cloth that encases at least a portion of the folded (compressed) airbag. The cover member can completely enclose the airbag, or it can enclose only a portion of the airbag. The key is that the cover member can maintain the shape of the airbag.

[0034] The hook portion of the wire passes through the patch opening and then the cover opening, preventing the cover member from shifting relative to the airbag and reliably maintaining the compressed shape of the airbag. The hook portion of the wire that passes through the cover opening can also be connected to a vehicle structure.

[0035] The guide member may be formed on the surface of the airbag in an overall L-shape.

[0036] The present invention is particularly effective when it is required to accommodate an airbag in a special L-shape.

[0037] A method for manufacturing an airbag device according to a second aspect of the present invention includes the steps of: accommodating the inflator inside the airbag; connecting the patch to the surface of the airbag by sewing; inserting and laying the wire inside the patch; causing the hook portion of the wire to protrude from the patch opening of the patch; folding or rolling the airbag along the outer circumferential shape of the wire; and covering the airbag with the cover member and causing the hook portion of the wire to protrude from the cover opening and engage. [Brief explanation of the drawings]

[0038] [Figure 1] FIG. 1 is a plan view showing the structure of an airbag device according to a first embodiment of the present invention, showing the airbag in a flat-laid state before being compressed. [Figure 2] FIG. 2 is a plan view showing the structure of a patch used in the airbag device according to the first embodiment of the present invention. [Figure 3] FIG. 3 is a cross-sectional view taken along the line A1-A1 in FIG. [Figure 4] Fig. 4(A) is a cross-sectional view taken along the line B1-B1 in Fig. 1. Fig. 4(B) is a cross-sectional view taken along the line C1-C1 in Fig. 1. [Figure 5] FIG. 5 is a plan view showing the structure of the airbag device according to the first embodiment of the present invention, illustrating the housed state after the airbag is compressed. [Figure 6] FIG. 6 is a cross-sectional view taken along the line E1-E1 in FIG. [Figure 7] FIG. 7 is a plan view showing the structure of an airbag device according to a second embodiment of the present invention, in a state where the airbag is laid flat before being compressed. [Figure 8] FIG. 8 is a cross-sectional view taken along the line B2-B2 in FIG. [Figure 9] FIG. 9 is a plan view showing the structure of an airbag device according to a third embodiment of the present invention, in a state where the airbag is laid flat before being compressed. [Figure 10]Fig. 10(A) is a cross-sectional view taken along the line A3-A3 in Fig. 9. Fig. 10(B) is a cross-sectional view taken along the line B3-B3 in Fig. 9. DETAILED DESCRIPTION OF THE INVENTION

[0039] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a detailed description will be given of first to third embodiments of the present invention with reference to the accompanying drawings.

[0040] (First Example) Fig. 1 is a plan view showing the structure of an airbag device 10 according to a first embodiment of the present invention, showing the airbag 14 in a flat-laid state before being compressed. Fig. 2 is a plan view showing the structure of a patch 26 used in the airbag device 10 according to the first embodiment of the present invention. Figs. 3, 4(A), and 4(B) are cross-sectional views taken along the lines A1-A1, B1-B1, and C1-C1 of Fig. 1, respectively.

[0041] The airbag device 10 according to this embodiment includes an airbag 14 that is inflated and deployed by gas supplied from an inflator 12; and a guide member 16 that is connected to the surface of the airbag 14 and regulates the outer peripheral shape of the airbag 14 when stored. The airbag device according to this embodiment can be used for motorcycles, for example. In addition to motorcycles, the present invention is particularly effective in airbag devices with limited storage space. The airbag device 10 according to this embodiment is designed for a case in which the storage space (housing) of the device is L-shaped.

[0042] 3, the inflator 12 is a disk-shaped inflator, and is fixed to the vehicle by stud bolts 22 passing through the four corners of a flange portion 20. The inflator 12 is housed inside the airbag 14 near the lower end of the airbag 14.

[0043] 1, the airbag 14 has a rectangular shape with a horizontally long lower portion, which widens upward into a circular shape. The airbag 14 can be formed into a bag shape by sewing two pieces of base fabric of the same shape together at their outer edges.

[0044] 1, the guide member 16 includes a wire 24 made of metal or resin disposed on the surface of the airbag 14, and a patch 26 that houses the wire 24. Although the wire 24 is located inside the patch 26 and cannot be seen from the outside, it is shown by a solid line in FIG.

[0045] 1, the patch 26 is a piece of cloth like a patch, has an area smaller than the airbag 14 when laid flat, is sewn to the surface of the airbag 14 to form a bag-like shape, and accommodates the wire 24 inside. The patch 26 overlaps the inflator 12 and is sewn to a position so as to cover the inflator 12.

[0046] 1 and 3, a portion of the wire 24 is secured so as to be wound around the outer periphery of the stud bolt 22 of the inflator 12. Although the wire 24 is shown as an endless loop in FIG. 1, it may also have a shape with two ends. Using a wire 24 with ends makes it easier to bend and wind.

[0047] 1, the wire 24 and the patch 26 have generally similar overall shapes, and the wire 24 is restricted from spreading any further by a sewn portion 27 of the patch 26. The wire 24 and the patch 26 are installed on the surface opposite to the side that faces the occupant when the airbag 14 is deployed.

[0048] 1 and 4(B), hook portions 24a to 24e are formed on a portion of the wire 24, protruding in a direction away from the surface of the airbag 14. These hook portions 24a to 24e are formed by bending a portion of the wire 24 into a U-shape. Note that although the hook portions 24a, 24b, 24d, and 24e protrude inward in FIG. 1, in reality, they protrude in a direction perpendicular to the plane of the paper.

[0049] As shown in FIG. 2, the patch 26 has patch openings 26a to 26e through which the hook portions 24a to 24e of the wire 24 pass.

[0050] By passing the hook portions 24a to 24e of the wire 24 through the patch openings 26a to 26e, the positional relationship between the patch 26 and the wire 24 is maintained, and unnecessary movement or deformation of the wire 24 inside the patch 26 can be prevented.

[0051] Fig. 5 is a plan view showing the structure of the airbag device 10 according to the first embodiment of the present invention, illustrating the housed state after compressing the airbag 12. Fig. 6 is a cross-sectional view taken along the line E1-E1 in Fig. 5.

[0052] 5, the airbag 14 is compressed by a roll on the surface opposite to the patch 26, as shown in FIG. 6. When the airbag 14 is compressed, it is rolled or folded along the outer edge of the wire 24. The outer edge of the compressed airbag 14 generally coincides with the outer edge of the patch 26, and is generally similar in shape to the patch 26 in plan view.

[0053] 5 and 6, the airbag device 10 according to this embodiment includes a cover member 30 that covers the outer periphery of the airbag 14 in a stored state. The cover member 30 maintains the shape of the airbag 14 when stored. The cover member 30 is made of flexible fabric and encases the airbag 14, resembling a furoshiki wrapping cloth. The cover member 30 has cover openings 34a to 34e formed therein, through which the hook portions 24a to 24e of the wire 24 that protrude from the patch openings 26a to 26e pass.

[0054] In this embodiment, the hook portions 24a to 24e of the wire 24 pass through the patch openings 26a to 26e and further through the cover openings 34a to 34e, so that the cover member 30 does not shift relative to the airbag 14, and the compressed shape of the airbag 14 can be reliably maintained.

[0055] As shown in Fig. 5, the cover member 30 covers one side (the opposite side of the paper) of the compressed airbag 14, and does not cover the central portion of the other side (the side facing the paper). The cover member 30 is designed to tear as the airbag 14 inflates and deploys. For example, the cover openings 34a to 34e can be torn by the tension of the airbag 14 when it inflates and deploys, or a slit can be formed in part of the cover member 30 to weaken it, and the slit can be torn. When the cover member 30 is torn, the airbag 14 is fully deployed.

[0056] (Airbag storage procedure) In this embodiment, an airbag 14 containing an inflator 12 is prepared, and a portion of a patch 26 is connected to the surface of the airbag 14 by sewing. For example, in FIG. 1, the entire outer periphery of the patch 26 is sewn except for the lower edge. This is to ensure a gap for inserting the wire 24. Next, with the lower side of the patch 26 spread out, the wire 24 is inserted inside the patch 26, and a portion of the wire 24 is wound around the stud bolt 22 of the inflator 12. Next, the wire 24 is bent to form hook portions 24a to 24e, which are then passed through patch openings 26a to 26e and exposed to the outside. After that, the lower edge of the patch 26 is sewn.

[0057] Next, the airbag 14 is folded or rolled along the outer peripheral shape of the wire 24, compressing the airbag 14 onto the surface opposite the wire 24 and patch 26. Next, as shown in Fig. 5, the compressed airbag 14 is wrapped in the cover member 30. Then, the hook portions 24a to 24e of the wire 24 are protruded and engaged through the cover openings 34a to 34e.

[0058] (Second Example) Fig. 7 is a plan view showing the structure of an airbag device 110 according to a second embodiment of the present invention, showing the airbag laid flat before being compressed. Fig. 8 is a cross-sectional view taken along the line B2-B2 in Fig. 7.

[0059] In the first embodiment, as shown in FIG. 1, a patch 26 is used as a means for holding the position of the wire 24, but in this embodiment, as shown in FIG. 7, the wire 24 is held on the surface of the airbag 14 by a plurality of loop-shaped holding members 126a to 126g.

[0060] As shown in Fig. 8, the retaining members 126a to 126g are formed into loops similar to trouser belt loops by sewing both ends of a strip of fabric to the surface of the airbag 14. The wire 24 is passed through this loop. Note that the number and positions of the retaining members are not limited to the example shown in Fig. 7, and are preferably changed as appropriate taking into consideration the size and compressed shape of the airbag.

[0061] The other configurations are the same as those of the first embodiment described above, so a duplicated description will be omitted.

[0062] (Airbag storage procedure) In this embodiment, retaining members 126a to 126g are connected to seven locations on the surface of the airbag 14 by sewing, and the inflator 12 is housed inside the airbag 14. Next, the wire 24 is passed through and fixed to the retaining members 126a to 126g. At this time, a portion of the wire 24 is wound around the stud bolt 22 of the inflator 12. Next, the wire 24 is bent to form the hook portions 24a to 24e. Subsequently, the airbag 14 is folded or rolled along the outer circumferential shape of the wire 24, and the airbag 14 is compressed onto the surface opposite the wire 24. Thereafter, as in the first embodiment, the compressed airbag 14 is wrapped in the cover member 30, and the hook portions 24a to 24e of the wire 24 are protruded and engaged through the cover openings 34a to 34e. (Third Example) Fig. 9 is a plan view showing the structure of an airbag device 210 according to a third embodiment of the present invention, showing the airbag laid flat before being compressed. Fig. 10(A) is a cross-sectional view taken along the line A3-A3 in Fig. 9. Fig. 10(B) is a cross-sectional view taken along the line B3-B3 in Fig. 9.

[0063] In the first and second embodiments described above, the wire 24 is used as a guide member for regulating the compressed shape of the airbag 14, but in this embodiment, a resin plate-like member 224 is used instead of the wire 24.

[0064] 9 and 10(A), the plate-like member 224 is formed with an opening 224x through which the main body of the inflator 12 passes, and openings 224a to 224d through which the stud bolts 22 of the inflator 12 pass. The plate-like member 224 can be positioned on the surface of the airbag 14 by these openings 224x and 224a to 224d.

[0065] A patch 226 similar to that in the first embodiment is provided on the plate-like member 224, and as shown in FIG. 10(B), the outer periphery of the patch 226 is sewn to the airbag 14 to accommodate the plate-like member 224.

[0066] (Airbag storage procedure) In this embodiment, an airbag 14 containing an inflator 12 is prepared, and a portion of a patch 226 is connected to the surface of the airbag 14 by sewing. For example, in FIG. 9, the entire outer periphery of the patch 226 is sewn except for the lower edge of the patch 226. This is to ensure a gap for inserting the plate-like member 224. Next, with the lower side of the patch 226 spread out, the plate-like member 224 is inserted into the interior of the patch 226, and the openings 224x, 224a to 224d of the plate-like member 226 are engaged so as to cover the main body of the inflator 12 and the stud bolts 22. Thereafter, the lower edge of the patch 226 is sewn, and the entire periphery of the patch 226 is sewn.

[0067] Next, the airbag 14 is folded or rolled along the outer peripheral shape of the plate-like member 224, and the airbag 14 is compressed onto the surface opposite the plate-like member 224 and the patch 226. Next, the compressed airbag 14 is wrapped in the cover member (30), thereby completing the airbag module. In this embodiment, since the airbag 14 is compressed (folded or rolled) based on the plate-like member 224, the shape of the compressed airbag 14 can be maintained flat, and the retention performance of the airbag 14 is improved.

[0068] While the present invention has been described in conjunction with the above exemplary embodiments, many equivalent modifications and variations will be apparent to those skilled in the art given this disclosure. Accordingly, the above exemplary embodiments of the present invention are considered to be illustrative and not limiting. Various changes may be made to the described embodiments without departing from the spirit and scope of the invention.

Claims

1. An airbag that is inflated and deployed by gas supplied from an inflator; a guide member connected to a surface of the airbag and regulating the outer peripheral shape of the airbag when stored; The inflator is housed inside the airbag, the guide member includes a wire made of metal or resin, When the airbag is stored, it is folded along the outer circumferential shape of the wire, An airbag device, wherein a part of the wire is clamped by a fastener of the inflator.

2. 2. The airbag device according to claim 1, wherein the airbag is folded or rolled into a shape that conforms to the outer periphery of the guide member.

3. 3. The airbag device according to claim 1, wherein the guide member is made of a material having a higher rigidity than the airbag.

4. 4. The airbag device according to claim 1, wherein a patch is provided on a surface of the airbag to cover the guide member.

5. 2. The airbag device according to claim 1, wherein the wire defines an outer periphery of the guide member.

6. 6. The airbag device according to claim 1, wherein a portion of the wire is positioned by engaging with a stud bolt of the inflator.

7. 7. The airbag device according to claim 1, wherein a plurality of loop-shaped wire holding members for holding the wire are provided on a surface of the airbag.

8. 8. The airbag device according to claim 1, wherein a hook portion is formed on a portion of the wire so as to protrude in a direction away from the surface of the airbag.

9. A patch covering the wire is provided on the surface of the airbag, 9. The airbag device according to claim 8, wherein the patch has a patch opening through which the hook portion passes.

10. A cover member that covers the outer periphery of the airbag in a stored state is further provided, 10. The airbag device according to claim 9, wherein the cover member has a cover opening through which the hook portion protruding from the patch opening passes.

11. 11. The airbag device according to claim 1, wherein the guide member is formed on the surface of the airbag in an L-shape as a whole.

12. A method for manufacturing an airbag device according to claim 10, comprising: housing the inflator within the airbag; connecting the patch to a surface of the airbag by sewing; Inserting and laying the wire inside the patch; causing a hook portion of the wire to protrude from the patch opening of the patch; folding or rolling the airbag to conform to the outer circumferential shape of the wire; and covering the airbag with the cover member and causing the hook portion of the wire to protrude from an opening in the cover and engage with the airbag.

Images